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'cav Dpa Pump Rebuild Manual'



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Section Ca6DESCRIPTION OF THE FUEL INJECTION PUMP The injection pump is a singlecylinder opposedplunger inletmetering pump fittedwith a mechanical flyweighttype governor and a hydraulically operated automatic advance mechanism Thepump is flangemounted on the rear of the engine frontmounting plate and is driven by the timing chain Asplined quill shaft having a master spline at each end Fig Cal Main fuel filter air bleed points 1 Fuel cutoff tap 2 Blanking plug 3 Union screw Taxi Issue 2 55430 THE FUEL SYSTEM Injection Pump Ca close fit in the stationary hydraulic head The pumping section of the rotor has a transverse bore containing twin opposed pumping plungers These plungers are operated by means of a cam ring carried in the pump housing through rollers and shoes which slide in the rotor The cam ring has four internal lobes operating in diagonally opposite pairs The opposed plungers have no return springs but are moved outwards by fuel under pressure from the transfer pump the flow of fuel and outward displacement of the plungers being determined by the setting of the metering valve and the speed at which the pump is rotating As a result the rollers which operate the plungers do not follow the contour of the internal cam ring entirely but will contact the cam lobes Fig Ca2 at points which will vary according to the amount of Fuel injection pump air bleed points plunger displacement 1 Union nut 2 Air bleed screw 3 Air bleed screw The automatic light load advance mechanism operates by rotating the cam ring within the pump body A ball ended lever screwed into the cam ring is operated byto ensure correct location transmits the drive from the a piston one side of which is springloaded sliding in achain wheel to the injection pump drive hub cylinder The other side of the piston is subjected to fuel A central rotating member forms the pumping and at transfer or drain pressure according to engine rotor and this is driven by the drive hub which is admitted to the cylinder through the hollowthrough a splined drive shaft on which is mounted the locating bolt and a port in the cylinder wall The flyweight assembly of fuel is controlled by the rotary and endwise movement Mounted on the outer end of the pumping and of the metering rotor is a transfer pump Machined in the surface of the metering valve is aThis pump raises the fuel pressure to an intermediate helical groove A vertical flat extends upwards from thelevel and as its capacity is many times the maximum helical groove and protrudes beyond the hydraulic of the injection pump a regulating valvehoused in the pump end plate allows excess fuel to bebypassed back to the suction side of the transfer pump A B The pressure regulating valve in addition to regulatingthe pressure of the fuel from the transfer pump alsoprovides a means of bypassing the transfer pump whenpriming the injection pump Referring to Fig Ca3 itwill be seen that the valve is cylindrical and containsa small free piston the travel of which is limited bytwo light springs When priming the injection pump fuelat lift pump pressure enters the central port in sleeve and moves the free piston againstthe pressure of the piston retaining spring to uncover thepriming port in the lower end of the valve sleeve Thepriming port is connected by a passage in the end plateto the delivery side of the transfer pump thus enablingthe fuel to bypass the stationary transfer pump andprime the injection pump When the injection pump is in operation fuel at enters the lower end of the valve sleeve forcingthe free piston upwards against the regulating springAs the engine speed increases the transfer pressure rises Fig Ca3moving the piston against the pressure of the regulating Section through the end plate and regulating valvespring to progressively uncover the regulating port in A Priming 7 Regulating pistonthe valve sleeve and allow a metered flow of fuel to by B Regulating 8 Piston retaining springpass back to the inlet side of the transfer pump 1 Inlet connection 9 Fuel passage to transfer The transfer pressure therefore is controlled by a 2 Sleeve retaining spring pump inletbalance between the regulating spring pressure and the 3 Nylon filter 10 Regulating port 4 Sleeve guide plug 11 Fuel passage to of the injection pump at any moment 5 Regulating spring pump outlet The pumping and distributing rotor revolves and is a 6 Regulating sleeveTaxi Issue2 3125 Ca5Ca THE FUEL SYSTEM Injection Pump Fig Ca4 Section through the fuel injection pump 1 Backleakage connection 5 Transfer pump 9 Pumping plunger 2 Governor spring 6 Hydraulic head 10 Drive plate 3 Metering valve 7 Cam ring 11 Governor weight assembly 4 End plate and regulating valve 8 Automatic advance device 12 Quill shaftThis flat is open to fuel at drain pressure in the governor The under side of the metering valve is subject to fuelhousing at transfer pressure which tends to force the valve In the surface at the lower end of the metering valve is upwards This upward movement of the valve is conmachined a flat the upper edge of which is of the same trolled by an adjustable stop screw which sets thepitch as the helical groove This flat is open to fuel at relative positions of the helical groove the flat on thetransfer pressure lower end of the valve and the timing port so that light The width of the land between the helical groove and load advance is obtained at the required engine speedthe flat at the lower end of the metering valve is slightly Machined on each lobe of the cam ring than the diameter of the timing port in the metering after the peak of the cam is a retraction curve Undervalve chamber in the hydraulic head The timing port running conditions when the injection cycle is completedwhich is situated opposite the metering port is connected the distributing port in the rotor and the outlet port onby a passage in the hydraulic head and the hollow the hydraulic head are still in partial alignment withlocating bolt to the port in the advance cylinder each other As the plunger rollers move off the peaks of When the metering valve is in the fullload position the cams the retraction curves allow the plungers tothe helical groove in the valve is aligned with the timing move slightly outwards This movement of the plungersport in the hydraulic head and fuel at drain pressure is effects a sudden reduction of pressure in the to the advance piston As the drain pressure is line so preventing secondary injection and allowing to overcome the piston spring pressure the injector nozzle needle valve to snap onto its seating tocam ring is held in the fully retarded position terminate the spray of fuel into the combustion chamber Under lightload conditions the metering valve is without dribble When starting the engine the meteringmoved to the low fuelling position aligning the flat at valve is in the fullload position and the advance pistonthe lower end of the metering valve with the timing port is subject to fuel at drain pressure As drain pressure isThe advance piston is now subject to fuel at transfer not sufficient to overcome the pressure of the and the piston and cam ring move to the fully piston return spring the piston and the cam ring remainadvanced position in the fully retarded positionCa6 Taxi Issue 2 3125 THE FUEL SYSTEM Injection Pump Ca The distributor part of the rotor has a central axialpassage which connects the pumping space between theplungers with the four inlet ports and single drilled radially in the rotor The radial hole at theouter end of the rotor is the distributing port and asthe rotor turns this port is aligned successively withthe outlet ports in the hydraulic head from which theinjectors are fed via external highpressure pipes Theinlet or charging ports are equally spaced around therotor at an intermediate position and as the rotor turnsthese are aligned successively with the inlet or meteringport in the hydraulic head This port admits fuel to therotor under control of the metering valve which ismechanically governed The mechanical governor is of the flyweight type theweights being held in a retainer which is clampedbetween the injection pump drive hub and the driveshaft and rotates with these components as a single unitThe weights are a sliding fit in the retainer pockets andare so shaped that when under the influence of centrifugal force they pivot about one edge A thrust sleevewhich is a sliding fit on the injection pump drive shaft Fig Ca6is moved axially by the flyweights Movement of the Mechanical governorthrust sleeve is transmitted by means of the governor 1 Governor weight 9 Metering portarm and the springloaded hook link to rotate the 2 Governor arm 10 Metering valvemetering valve The governor arm pivots about a fulcrum 3 Shutoff bar 11 Timing porton the control bracket and is held in contact with the 4 Shutoffshaft 12 Control bracketthrust sleeve by spring tension Connection between the 5 Idling spring 13 Drive shaft 6 Governor spring 14 Thrust sleevegovernor arm and the throttle arm and shaft assembly is 7 Throttle shaft 15 Weight retainermade through the governor spring and the idling spring 8 Linkage hookand its guide A shutoff bar operated by an external lever rotatesthe metering valve to close the metering port The metering valve is provided with a vertical slot along which fuel passes at transfer pressure into the metering port The valve is situated in a chamber in the hydraulic head into which the diagonally drilled metering port opens and rotation of the valve varies the effective area of the metering port to regulate the flow of fuel to the pumping and distributing rotor When the throttle arm is moved to give increased speed the light idling spring is compressed as the guide is drawn through the governor arm and the governor spring is tensioned Tension of the governor spring acting upon the governor arm and thrust sleeve resists move ment of the governor flyweights As the engine speed increases the increasing centrifugal force moves the flyweights outwards overcoming the governor spring tension to move the governor arm and the metering valve towards the closed position When the selected speed has been attained it will be maintained by governor action Should the engine speed fall the flyweights will move inwards causing an increase of fuelling which A restores the selected engine speed When the throttle arm is in the idling position the Fig Ca5 governor spring is untensioned and governing action is Lightload advance device controlled by the light idling spring A Full load 1 Transfer pressure In operation fuel at lift pump pressure enters the pump B Low load 2 To pumping element through the connection on the pump end plate and passesTaxi Issue2 81968 Ca7Ca THE FUEL SYSTEM Injection Pump through a fine nylon gauze filter to the inlet side of the 1transfer pump From the transfer pump the fuel passes through a passage in the hydraulic head to an annular the rotor and thence to the metering valveThe position of the metering valve depends upon the Asetting of the throttle arm which varies the governorspring pressure on the governor arm Any variation inpump speed is accompanied by an increase or decreasein transfer pressure which assists in regularing the flowof fuel into the pumping section of the rotor Thevolume of fuel passing into the pumping element is thuscontrolled by the transfer pressure the position of themetering valve and the time during which an inlet portin the rotor is aligned with the metering port in thehydraulic head B When one of the rotor inlet ports is aligned with themetering port in the hydraulic head fuel at flows into the rotor and forces the apart the amount of plunger governed by the quantity of fuel which can flow Fig Ca8into the rotor while the ports are aligned As the rotor The injection cycleturns the inlet port is cut off and the pump plungersbegin to be forced inwards by their rollers bearing on a A Inlet stroke 2 Pumping and distributing rotor B Injection stroke 3 Pumping plungerspair of cam lobes This causes an immediate rise in 1 Fuel inlet 4 Fuel to as the single distributor port in the rotorcomes into register with an outlet port in the hydraulic engage eccentric slots in the top and bottom adjustinghead the plungers force the fuel up the central bore of plates Two lugs on the top adjusting plate engage slotsthe rotor and out to the respective injector in the bottom adjusting plate to locate the plates one to The maximum amount of fuel delivered at one charge the otheris controlled by limiting the maximum outward move The top adjusting plate isclamped to the rotor byment of the plungers In Fig Ca7 is shown an endon the drive plate the adjusting plate being cut away inview of the rotor and it will be seen that the cam rollers the areas of the drive plate securing screws to permitare carried in shoes which bear against the ends of the adjustment of the plates by rotation The maximum outplungers The roller shoes which slide in slots in the ward travel of the pump plungers is limited by the earsrotor have specially shaped projecting ears which of the roller shoes coming into contact with the curved slot sides in the adjusting plates As the slots are eccentric rotation of the adjusting plates relative to the rotor provides a means of adjusting the maximum plunger stroke Section Ca7 REMOVING AND REPLACING THE FUEL INJECTION PUMP Thoroughly clean the outside of the injector pump body and then disconnect the throttle stop and kick down if fitted controls Disconnect the fuel feed and return pipes from the pump Disconnect the high pressure pipes from the pump and the injectors remove the clamp and damper bushes and detach the pipes individually from the engine Seal the pump outlet unions with sealing caps 18G 216 to prevent the ingress of foreign matter Fig Ca7 Unscrew the three nuts with plain washers securing the Maximum fuel adjustment injection pump flange to the rear of the engine front plate 1 Top adjusting plate 4 Pumping end of rotor and draw the pump rearwards to disengage it from the 2 Roller shoe ear 5 Pumping plunger engine Withdraw the quill shaft from inside the injection 3 Roller pump chain wheel hubCa8 Taxi Issue 3 94241 THE FUEL SYSTEM Injection Pump Before replacing the fuel injection pump it is necessary Place a new joint washer in position on the engine frontto set the static injection timing plate and offer up the injection pump to the engine To ensure correct timing relationship between the Engage the pump drive hub with the quill shaft andinjection pump and the engine the injection pump driving retain the pump in position by fitting the securing nutshub the quill shaft and the driving flange of the injection and washers finger tight Rotate the injection pump topump chain wheel are provided with master splines also align the timing mark on the pump mounting flangea timing mark is scribed on the fuel injection pump with the timing pointer Tighten the three nuts to securemounting flange and an adjustable timing pointer is the injection pump in this to the flange of the chain wheel hub Refit the highpressure pipes and the fuel feed and Before fitting the injection pump to the engine the drain pipes Connect the throttle and shutoff of the timing pointer on the flange of the chain and ensure that both controls have their full range ofwheel hub should be checked using timing gauge movement 18G 698 and reset if necessary Bleed the fuel system as described in Section Ca5 A degree plate fitted to the crankshaft pulley with acorresponding pointer on the timing case is provided to Maximum and idling speed ease of timing After fitting either a new or overhauled injection pump Initial adjustment of the injection timing is provided for the engine maximum light running speed and the idlingin the injection pump driving flange the holes for the speed must be checked and adjusted if necessary Beforebolts which secure it to the chain wheel being elongated making either of these adjustments it is imperative that Crank the engine until the appropriate timing mark the engine air cleaner is correctly serviced and with the timing groove on the crankshaft Run the engine until it has attained its normal runningpulley Ensure that No 1 piston is on its compression most important Ensure that the shutstroke off control is in the fully open position and remove the Remove the injection pump chain wheel coverplate locking sleeve from the maximum speed adjusting screw From the front of the timing chain case and note the Using a tachometer to check the engine speed adjust position of the master spline in the pump driving flange the maximum speed stop screw to give a maximum light which should now be in the seven oclock position as running speed of 3700 rpm thus giving a maximum seenfrom the front of the engine road governed speed of 3500 rpm Tighten the locknut Insert injection timing gauge 18G 698 through the Fit the locking sleeve and seal it with wire and a lead chain wheel hub engaging the splined end of the gauge seal using sealing pliers 18G 541 with the internal splines of the pump driving flange The Adjust the idling stop screw to give an idling speed of master spline will allow the gauge to engage the driving 600 rpm and tighten the locknut flange in one position only Turn the gauge by hand undue force is not necessary in a clockwise direction as seen from the rear of the engine to take up anybacklash in the injection pump drive mechanism Hold Section Ca8 the gauge in this position slacken the two securing DISMANTLING AND REASSEMBLING THE screws and move the timing pointer to align it with the FUEL INJECTION PUMP slot on the edge of the gauge Should the movement required to line up the timing pointer be appreciable Dismantling and servicing of the fuel injection pumpthen initial adjustment should be made by altering the should only be carried out by specially trained of the injection pump driving flange relative tothe chain wheel This adjustment is made by slackeningthe four bolts securing the driving flange to the chainwheel and carefully turning the driving flange therequired amount by means of the timing gauge Tightenthe driving flange securing screws and carry out of the timing pointer as described previouslyand then remove the timing gauge NOTEAfter every occasion of injection pump removal or attention to the crankshaft camshaft and timinggear the position of the timing pointer should be checkedand reset if necessary as described above Fit the injection pump quill shaft into the drivingflange Rotate the injection pump drive hub and position themaster spline in the drive hub at seven oclock when Fig Ca9looking on the drive end of the pump This will facilitatethe engagement of the quill shaft splines with the drive Checking the position o f the injection pump timinghub pointer using timing gauge 18G 698Taxi Issue 6 83137 Ca9Ca THE FUEL SYSTEM Injection Pumpand the Service tools and special test equipment referred slide washer and piston from inside the advance deviceto in the following instructions should be available The housing Remove and discard the O seals from theworkshop in which these operations are carried out spring cap and end plugshould be absolutely clean and the atmosphere free from Slacken the fuel inlet connection and then remove thedust or dirt It is also recommended that components screws and studs securing the end plate to the hydraulicare immersed in clean Shell Calibration Fluid C head Carefully remove the carbon vanes from their after they are dismantled from the main in the transfer pump rotor and withdraw the to protect them from possible damage and pump linercorrosion and to prevent the ingress of foreign matter Unscrew the fuel inlet connection and carefully with Abrasives should never be used for cleaning as the draw the components of the regulating valve from theresulting damage would seriously impair both the end plate in the following order sleeve retaining and the working life of the pump The com nylon filter regulating plug reguIating spring valveponents should be washed in clean Shell Calibration sleeve with piston and joint washer and lastly the pistonFluid C but they must not be wiped with cotton waste retaining springrags or cloth wipers of any kind Hold the drive hub with drive shaft screw assembly Cut the sealing wire remove the coverplate and joint tool 18G 659 and using box spanner 18G 634 in conjuncwasher from the side of the pump housing and drain the tion with a standard ratchet wrench slacken the transferfuel oil from the pump pump rotor The word OFF and an arrow etched on Withdraw the quill shaft from the drive hub and the exposed face of the rotor indicate the direction inmount the pump on assembly base 18G 633 A secured which the rotor is unscrewedin a vice Unscrew and remove the two hydraulic head locking Remove the banjo pipes from the hydraulic head screws one of which carries an air vent valve and careUnscrew the selflocking nuts with plain washers and fully withdraw the hydraulic head and distributing rotorreniove the shutoff lever and throttle arm from their assembly from the pump housing Remove the 0sealshafts Remove the dust cover from each shaft Cut the from the groove in the periphery of the hydraulic headlocking wire unscrew the two control cover securing Unscrew the transfer pump rotor taking care not tonuts and remove the two flat washers Press the throttle allow the pumping and distributing rotor assembly to fallshaft downwards and withdraw the control cover com out from the hydraulic headplete with shutoff shaft and adjusting screws Remove Stand the hydraulic head assembly on the bench withand discard the control cover to pump housing gaskets the drive plate uppermost Hold the drive plate with Press back the locking tabs and unscrew the two assembly spanner 18G641 and unscrew the two drivecontrol cover studs and the small set screw securing the plate securing screws Remove the drive plate lift offcontrol bracket to the pump housing Remove the keep the top adjusting plate and withdraw the rollers andplate and tab washers then lift the complete control roller shoes from the pumping and distributing rotorbracket assembly together with the metering valve and Withdraw the rotor from the hydraulic head and reshutoff bar from the pump housing Remove the shutoff move the bottom adjusting plate Refit the rotor to thebar from the control bracket Disconnect the metering hydraulic head and to protect the working surfacesvalve from the linkage hook and protect its precision immerse the assembly in a bath of clean Shell surface by immersing it in a bath of Shell Calibra Fluid Ction Fluid C Unscrew the selflocking nut and removethe nylon pivot washer to release the linkage hook from Withdraw the cam ring from the pump housingthe governor arm Disconnect the throttle shaft link from noting the arrow etched on the visible face of the camthe governor spring and remove and discard the two O ring The arrow is to assist when reassembling and ifsseals from the throttle shaft Disconnect the governor direction corresponds with the direction of pump rotaspring from the idling spring guide and withdraw the tion as shown on the pump nameplateguide and spring from the governor arm Remove the Compress the cam ring locating circlip using arm spring to release the governor arm from pliers 18G 1004 and withdraw the circlip from inside thethe control bracket pump housing Turn the pump upsidedown and slacken both the Hold the drive hub with drive shaft screw assemblyspring cap and the end plug in the advance device tool 18G 659 and using torque adaptor 18G 664 and ahousing until the pressure of the maximum advance stop standard socket wrench unscrew the drive shaft screwspring inside the advance device housing is relieved from inside the drive hub reversing the procedure shownIJnscrew the cap nut and the head locating bolt both in Fig Ca12 The splined drive shaft complete withof which have aluminium and rubber sealing washers governor weights assembly may now be withdrawn fromand remove the advance device housing Unscrew and inside the pump housingremove the advance screw from the cam ring Remove Remove and discard the 0seal from the drive shaftand discard the advance device housing gasket and remove the weight retainer weights thrust washer Unscrew the end plug and the spring cap noting the and sleeve from the drive shaftadjusting shim inside the cap Withdraw the spring stop Withdraw the drive hub from inside the pump housingca10 Taxi Issue 6 83137 THE FUEL SYSTEM Injection Pump Caand remove the spring washer and support washer fromtheir location inside the drive hub The washers areremoved by turning them end on inside the drive hub andwithdrawing them along the master spline Two flats aremachined on the outside diameter of the support washerto facilitate this operation Remove the drive hub oil seal from the pump housingusing oil seal extractor tool 18G 658 Wash all components thoroughly in clean Shell Calibration Fluid C Cotton waste rags or cloth wipersmust not be used to wipe the components If the plug with sealing washer using rotor plugspanner 18G 652 and blow out the internal passages inthe pumping and distributing rotor with compressed airCoat the threads of the plug with Araldite and refit andtighten the plug to 28 Ib in 32 kg m Push out the pumping plungers one at a time forinspection noting that the end of the plunger which hasbeen in contact with the roller shoe is polished andshould be replaced in this position Examine the working Fig Callsurface of the plungers and the plunger bore in the pumping and distributing rotor for wear and abrasions The Removing the drive hub oil seal using oil seal extractorbore of the hydraulic head and its mating surface in the 18G 658rotor should also be examined for wear and scoringShould any of these parts be worn the pumping rotor and hydraulic head which are mated guides in the pumping and distributing rotor for must be renewed as a unit action and freedom of movement Some injection pumps are fitted with hydraulic heads Check the drive shaft splines for wear assemble thehaving an oversize metering valve bore and an oversize drive shaft to the drive plate and ensure that there is nometering valve to suit Oversize metering valves which excessive radial movement between the drive shaft andare identified by a machined groove are available but plateonly hydraulic heads having a standardsize metering valve Test the fit of the vanes in their slots in the transferbore are supplied as replacements Injection pumps fitted pump rotor The vanes should be a sliding fit whenwith oversize metering valves are identified by the number lubricated with fuel oil6375 etched upon the hydraulic head between the outlet Inspect the bore of the regulating valve sleeve for adjacent to the metering valve bore and ensure that the valve piston can move freely along Inspect the plunger rollers for flats and the cam ring the whole length of the sleeve borelobes for signs of wear Test the roller shoes in their Inspect all springs for fractures and check them against new counterparts for length Weak or fractured springs should be renewed Check the governor weight retainer thrust washer and thrust sleeve against new counterparts for signs of wear When reassembling thoroughly rinse all components in freshly filtered clean Shell Calibration Fluid C and assemble all parts wet Fit a new drive hub oil seal to the pump housing driving it onto its seat with oil seal guide 18G 663 Insert oil seal inspection plug 18G 660 into the oil seal A correctly fitted oil seal will show a continuous black line when viewed through the flange end of the oil seal inspection plug Fit the support washer and spring washer into the drive hub Remove the oil seal inspection plug and pass A51471 the drive hub through the seal seating the drive hub flange against the pump housing Fig Ca10 Place the governor weight retainer on plate 18G662 Holding the drive plate with spanner 18G 641 when and pass locating pin 18G 661 through the weight unscrewing the drive plate securing screws retainer to locate in the plate so that the weight retainerTaxi Issue3 6394 Ca11 Ca THE FUEL SYSTEM Injection Pump is trapped between the plate and the shoulder of the locating pin Place the weights equally spaced in position on the weight retainer The slot in each weight should be uppermost and nearest the locating pin Fig Ca 13 Each weight should be aligned with a pocket in the weight retainer and with its inner end against the locating pin Place the thrust washer and thrust sleeve on the locating pin and resting on the governor weights The thrust sleeve must be fitted with the flange having the projection uppermost Exert downward pressure on the thrust sleeve and the assembly will enter the weight retainer Withdraw the locating pin and remove the assembly from the plate Slide the assem bly onto the drive shaft Fit protection cap 18G 657 over the drive shaft splines and fit a new 0 seal in the machined groove on the shaft Insert the drive shaft and weight assembly into the pump housing and engage the drive shaft splines with the splines in the drive hub Fit the drive shaft screw and holding the drive hub with Fig Ca13 drive shaft screw assembly tool 18G659 tighten the Assembling the governor weights thrust washer and drive shaft screw to the figure given in GENERAL thrust sleeve into the weight retainer using Service DATA using torque adaptor 18G664 and torque tools 18G 661 and 18G 662 wrench 18G 537 Fig Ca12 Compress the cam ring locating circlip using circlip stamped on the periphery of the pumping end of the rotor pliers 18G 1004 and seat it against the shoulder in the corresponds with the pump rotation as indicated on theboreof the pump housing Place the cam ring in position pump nameplate against the circlip The direction of the arrow on the Withdraw the pumping and distributing rotor complete visible face of the cam ring must conform with the with plungers from the hydraulic head Place the top direction of pump rotation as marked on the pump adjusting plate in its correct position on the rotorthat nameplate Fit the cam advance screw finger tight to is with the slot in the periphery of the adjusting plate locate the cam ring and check the ring for freedom of aligned with the scribed mark on the periphery of the movement in the pump housing pumping end of the rotor Fig Ca14 If the hydraulic head and pumping and distributing Fit the drive plate to the rotor with its relieved face rotor are renewed ensure that the direction of the arrow next to the top adjusting plate The slot in the periphery of the drive plate must be in line with the scribe mark on the periphery of the rotor Fig Ca14 Tighten the drive plate securing screws lightly to hold the top adjusting plate in position on the rotor Invert this assembly so that the distributing end of the rotor is upper most Slide the rollers into their shoes and insert the roller and shoe assemblies into their guides in the rotor ensuring that the contour of the roller shoe ears conforms with the contour of eccentric slots in the top adjusting plate Assemble the bottom adjusting plate to the rotor with the contour of the eccentric slots in the adjusting plate conforming to the contour of the roller shoe ears and the slots in the periphery of the bottom adjusting plate engaging the lugs on the top adjusting plate Fit the assembly of the pumping and to the hydraulic head and fit and lightly tighten the transfer pump rotor Stand the assembly of the hydraulic head and the pumping and distributing rotor on the bench with SA the pumping end of the rotor uppermost Fit relief valve timing adaptor 18G 653 A preset at 15 Fig Ca12 atmospheres to highpressure outlet V on the hydraulic Holding the drive hub with drive shaft screw assembly head and connect up the whole assembly to injector tool 18G 659 while tightening the drive shaft screw nozzle testing machine 18G 109 A Fig Ca15 with torque adaptor 18G664 and torque wrench Operate the handle of the test machine and turn the 18G 537 pumping and distributing rotor in the normal direction ofCa12 Taxi Issue3 6394 THE FUEL SYSTEM Injection Pump Ca rotation until the pumping plungers are forced outwards to the maximum fuel position Set the rollertoroller dimension using a micrometer to the dimension given in GENERAL DATA Move the adjusting plates clockwise to increase and anticlockwise to decrease the dimension with maximum fuel adjusting probe 18G 656 Tighten the drive plate securing screws to the figure given in GENERAL DATA using torque wrench 18G 537 This setting is approximate final adjustment being made with the pump mounted on a powerdriven test machine see Section Ca9 The drive plate is held when tighten ing the securingscrews with assembly drive plate spanner 18G 641 Disconnect the test machine and the hydraulic adaptor from the hydraulic head Fit a new oil seal into its groove in the machined periphery of the hydraulic head Turn the pump drive shaft in the pump housing and position the master spline at 12 oclock Align the masterspline in the drive plate with the metering valve bore inthe hydraulic head Lubricate the periphery of thehydraulic head and the bore of the pump housing Fig Ca15liberally with clean Shell Calibration Fluid C Hold thehydraulic head assembly square with the axis of the pump Setting the rollertoroller dimension using a microhousing and with the metering valve bore at 12 oclock meter and Service tools 18G 109 A and 18G 653 Apush the hydraulic head into the pump housing Rotatethe drive shaft slightly to assist the engagement of theshaft with the drive plate to the smalldiameter end of the regulating valve sleeve Insert the two hydraulic head locking screws leaving and insert the valve piston into the sleeve Insert thethem finger tight and ensuring that the screw with the regulating spring into the largediameter end of the valvevent valve is fitted immediately above the pump name sleeve Place the regulating plug on the top of the sleeveplate with its spigoted end engaging the sleeve bore Fit the Mount drive shaft screw assembly tool 18G 659 in the sleeve retaining spring onto the guide Pass the nylonsplined drive hub and using torque wrench 18G 536 and filter smalldiameter end leading over the spring andassembly box spanner 18G 634 tighten the transfer pump regulating plug onto the shoulder of the valve sleeverotor to the figure given in GENERAL DATA Insert this assembly valve sleeve first into the bore of Fit the transfer pump liner and insert the carbon vanes the end plate and secure it in position with the fuel inletinto the slots in the transfer pump rotor connection and washer Ensure that the transfer pump liner locating peg is in Position a new oil seal in its recess in the upper face ofposition C in the pump end plate the hydraulic head and fit the assembled end plate to the Insert the piston retaining spring into the regulating head engaging the locating peg on the inner face of thevalve bore in the end plate ensuring that it is properlyseated in the bottom of the bore Fit a new seal washer Fig Ca14 Assembly the top adjusting plate and the drive plate Fig Ca16 with the slots in their peripheries aligned with the Tightening the transfer pump rotor using torque scribed mark on the pumping end of the rotor wrench 18G536 and Service tools 18G 659 and 18G634Taxi Issue 4 88664 Ca13Ca THE FUEL SYSTEM Injection Pumpend plate with the slot in the periphery of the transferpump liner The end plate securing screw holes areunequally spaced to ensure correct assembly of the endplate to the hydraulic head Tighten the set screws andstuds to the torque figure given in GENERAL DATAusing torque wrench 18G 536 Tighten the fuel inlet connection to the torque figure in GENERAL DATAusing torque wrench 18G 537 Tighten the cam ring advance screw to the figure givenin GENERAL DATA using torque wrench 18G 372Check the cam ring for freedom of movement Place a new advance device housing gasket in positionon the pump housing with the flat of the Dshapedhole at the drive hub end of the pump To ensure satisfactory sealing this gasket should be assembled dryAssemble the advance device housing to the pump Fig Ca17housing using new rubber and aluminium sealing Setting the internal dimension between the for the head locating bolt and cap nut Using valve lever pin and the control cover stud with thetorque wrench 18G 537 tighten the head locating bolt vernier heldparallel to the axis of the pumpthe cap nut and the two head locking screws to thefigures given in GENERAL DATA Check the cam lever pin and its nearest control cover stud to the lengthring for freedom of movement given in GENERAL DATA using a vernier gauge as Fit new 0seals to the lightload advance piston plug shown in Fig Ca17 Adjustment is made by slackeningand the spring cap using protection cap 18G 640 to pass or tightening the hook linkage nut During this operationthe seals over the threads light pressure should be applied to the governor arm Insert the slide washer and piston in that order into in the direction of the metering valve and the vernierthe advance device housing on the side where the fuel gauge should be held parallel to the pump axisoil drilling enters the piston bore Screw in the piston Locate the idling spring on the idling spring guideplug Insert the maximum advance stop and spring in Insert the guide into hole No 2 in the governor armthat order into the remaining open end of the advance Fig Ca6 and connect the governor spring to the idlingunit housing and screw in the cap Tighten the piston spring guideplug and spring cap to the torque figures given in Insert the plain end of the shutoff bar into the slotGENERAL DATA using torque wrench 18G 537 in the control bracket and position the shutoff bar under Insert the metering valve into the metering valve bore the tab of the control cover stud locking washerin the hydraulic head Engage the governor arm with the control bracket Using protection cap 18G 564 fit the lower Oseal toand connect the governor arm spring to both components the shutoff shaft Fit the upper 0 seal using protection Fit the assembly governor arm and control bracket to cap 18G 665 Pack the groove between the 0seals withthe pump housing The lower end of the governor arm Shell Alvania No 2 grease Press the shutoff shaft intoshould engage the outside face of the thrust sleeve flange its bore in the control cover The peg which engages thePlace the keep plate in position with its open end towards shutoff bar should be close to the inside edge of the the shutoff bar Fit new tab washers with their pointed control cover and should be left projecting slightly abovetabs towards the governor arm Secure the keep plate in the control cover faceposition with the two governor control cover studs Fit Place a new control cover gasket in position on thethe small screw and tab washer at the metering valve end pump housing ensuring that the locating tabs of theof the control bracket Tighten the control cover studs to gasket engage the slots under the keep plate To ensurethe torque figure given in GENERAL DATA using satisfactory sealing this gasket should be soaked in Shelltorque wrench 18G 536 Lock the studs in position by Calibration Fluid C before assembly bending up the pointed tabs Tighten the small screw to Fit new lower and upper 0seals to the throttle shaftthe torque figure given in GENERAL DATA and lock using protection caps 18G 654 and 18G 665 Pack the it with the tab washer groove between the 0seals with Shell Alvania No 2 Assemble the spring retainer spring and fibre washer grease Connect the free end of the governor spring to onto the governor linkage hook in that order Pass the hole No 2 22litre engine or hole No 1 end of the linkage hook through the governor engine in the throttle shaft link Fig Ca6arm Fit the pivot ball washer onto the linkage hook Press the throttle shaft into its bore in the controland screw on the linkage nut about three turns Press cover Place the control cover in position on the control back the spring retainer and attach the linkage hook to cover studs Ensure that the shutoff shaft peg engagesthe metering valve The hook end should turn towards the shutoff bar and pull the shutoff shaft fully home the metering valve as the control cover is lowered onto the gasket Fit new Set the internal dimension between the metering valve sealing washers on the control cover studs and fit and Cu14 Taxi Issue 4 88664 THE FUEL SYSTEM Injection Pump Catighten the stud nuts to the torque figures given inGENERAL DATA using torque wrench 18G 536 Placethe dust caps on the throttle and shutoff shafts Fit thethrottle arm and the shutoff lever to their and secure them in place with their nuts Ca9 TESTING AND ADJUSTING THE FUEL INJECTION PUMP After overhaul the fuel injection pump must be and the maximum fuel output adjusted ifnecessary These tests and adjustments are carried out ona powerdriven test bench embodying the and pressure gauges and equipment to test thefuel transfer pump and a graduated glass to measure the Fig Ca18injection pump backleakage In addition the tools Checking the automatic advance device usingmentioned in the following paragraphs are also required advance gauge 18G 638 B NOTEThe following precautions must be observed Remove the small set screw from the centre of thewhen testing the pump advance unit housing spring cap and assemble automatic 1 Ensure that the powerdriven test bench is set to run advance gauge 18G 638 B to the spring cap with the in the direction of rotation of the injection pump as degree scale and pointer uppermost and the scale set to indicated by the arrow on the pump nameplate zero Serious damage may be caused to the pump if it is Throughout the following operations and tests the pump run in the reverse direction throttle and shutoff levers must be in the fully open 2 Ensure that the fuel flow at the pump inlet is not position except where stated otherwise less than 1000 ccmin If this flow cannot be The pump and the feed pipe must now be filled and obtained a maximum feed pressure of 2 lbsq in primed as follows 15 kgcm2 is permissible 1 Connect the fuel feed pipe to the drain connection 3 Do not run the pump for long periods at high speed on the pump housing with low fuel output 2 Open both of the vent screws on the injection 4 Do not run the pump for long periods with the shut pump off control in the closed position 3 Turn on the gravity feed When test oil free from air bubbles flows from the vent screw on the After checking the direction of rotation mount the hydraulic head close this vent screw Wait till thepump on the test bench and connect up the drive Fit test oil flowing from the vent screw in the governorradial connections to the hydraulic head in place of the control housing is free from air bubbles then closebanjo pipes Using highpressure pipes 6 mm x 2 mm x this vent screw also865 mm 34 in long connect the radial connections to 4 Rotate the pump drive through 180 and repeata matched set of test nozzles The test nozzles should be operations 2 and 3Type BDN12SD12 mounted in nozzle holders Type 5 Fit the feed and return pipes to their formerly BKB5OSD19b and set to at 175 atmospheres 6 Slacken the highpressure pipe unions at the Ensure that the pump throttle arm has the full range injector endof movement by unscrewing fully the idling and maximum 7 Start the test machine and run at 100 rpm untilspeed stop screws oil free from air bubbles issues from the injector Remove the hydraulic head locking screw not the one pipe the vent valve and connect the pressure 8 Tighten the injector pipe connection while the testgauge by means of a flexible pipe to transfer pressure machine is runningadaptor 18G 636 which is screwed into the head locking The following tests are designed to check in turn eachscrew hole of the separate functions of the injection pump Before Connect the feed pipe preferably of the transparent however making these individual tests a general checktype to the fuel inlet connection on the injection pump should be carried out to ensure oiltightness of all jointend plate The vacuum gauge should be fitted by means washers oil seals and pipe connections while the pumpof a T coupling to the feed pipe is running and when stationary Connect the inlet connection on the the drain connection on the pump housing and the 1 Transfer pump vacuum testdrain cock on the measuringglass to the return pipe on I Start the test machine and run the pump atthe test bench by means of flexible pipes 100 rpmTaxi Issue 4 6394 Ca15Ca THE FUEL SYSTEM Injection Pump 6 Fuel delivery check Without altering any of the adjustments check that the fuel delivery at 800 rpm is 36 to 44 CC per 200 shots Remove the shutoff lever adjust ment tool 7 Advance check Run the fuel pump at 800 rpm Move the shut off lever to the fully closed position and check that the advance reading is 312 to 4 12 Fit and seal the metering valve adjustment screw sealing cap with wire and a lead seal using sealing pliers 18G 541 NOTEIf for any reason it is found necessary to tighten or slacken the governor control cover cap A9255 nuts the settings made at 4 and 5 will be dis turbed and operations 4 5 6 and 7 should Fig Ca19 be repeated Adjusting the maximum fuel setting using Service 8 Backleakage tool 18G 656 Set the shutoff lever fully open and the throttle arm fully closed Run the pump at 1000 rpm Turn the test oil feed cock to the off position and measure the backleakage through the gradu and note the depression registered on the vacuum ated measuringglass The backleakage should be gauge This should build up to 1 6 in 406mm Hg 5 to 50 CC per 100shot cycle within 60 seconds maximum Check the fuel feed pipe unions for air leaks indicated by the presence 9 Maximum fuel setting of air bubbles in the pipe line If necessary NOTEThroughout this test the advance gauge tighten the feed pipe unions and carry out a further must show a zero reading test Run the pump at 1000 rpm with both controls NOTEDo not run the pump for periods ex in their fully open position when the average ceeding 60 seconds with the test oil supply turned off delivery for 200 shots from all four test injectors After the vacuum test is completed turn on the should be 6 9 1 CC In arriving at this figure test oil supply and with the pump running at compare the delivery from all injectors to ensure 100 rpm airvent the pump by means of the vent that the difference in output from any two does valve on the hydraulic head locking screw not exceed 6 CC Before taking a reading the test oil in the should be allowed to 2 Transfer pump pressure settle for 15 seconds and the With the pump running at 100 rpm note the should be allowed to drain for 30 seconds before pressure registered on the pressure gauge which a fresh test is made should read 12 lbsq in 8 kgcm2 To adjust the pump output stop the test bench 3 Transfer pump pressure and turn the test oil feed cock to the off position Increase the pump speed to 800 rpm when a Remove the coverplate from the side of the pump pressure of 32 to 44 lbsq in 23 to 31kgcm2 should be registered on the pressure gauge 4 Fuel delivery setting Run the pump at 800 rpm and after slackening the locknut alter the metering valve adjustment screw till a zero reading is obtained on the auto matic advance gauge Tighten the locknut and re check the advance reading Fit the shutoff lever adjustment tool 18G697 to the fuel pump and adjust the shutoff lever to obtain an average fuel delivery of 36 to 44 CC per 200 shots Ensure that the advance gauge still shows a zero reading 5 Advance setting Run the pump at 800 rpm Slacken the metering valve adjustment screw locknut and alter the adjustment screw to obtain an advance reading of Fig Ca20 134 to 214Tighten the locknut and recheck the The shutoff lever adjuster 18G697 mounted on the advance reading fuel injection pump and test benchCa16 Taxi Issue4 6394 THE FUEL SYSTEM Injection Pump Ca 11 Cutoff test With the shutoff lever held in the fully closed position run the pump at 200 rpm The average delivery for 200 shots with the throttle arm in the fully open position should not exceed 10 CC 12 Throttle operation Run the fuel pump at 200 rpm with the throttle arm in the fully closed position The average delivery with the shutoff lever fully open should not exceed 10 CC per 200 shots 13 Fuel delivery check With both controls fully open run the fuel pump at 1650 rpm and record the average delivery per 200 shots Fig Ca21 14 Governor setting Tightening the drive plate screws using torque wrench Increase the pump speed to 1850 rpm and set 18G 537 and torque adaptor 18G 655A the throttle arm by means of the maximum speed adjustment screw to give a maximum average delivery of 10 CC per 200 shots No line should exceed 18 CC Tighten the adjustment screw locknut 15 Fuel delivery check Reduce the pump speed to 1650 rpm and re housing to provide access to the interior of the check the fuel delivery The average delivery now pump Slacken the two drive plate securing screws should not be less than that recorded in operation sufficiently to permit movement of the adjusting 13 minus 4 CC per 200 shots plates Turn the pump drive until the slots in the peripheries of the drive plate and the top adjusting 16 Timing setting plate are visible through the aperture in the pump This setting is made after all the foregoing tests housing Engage the end of the maximum fuel have been completed with the pump removed adjusting probe 18G 656 in the slot in the top from the powerdriven test bench adjusting plate and tap the tool with a light It should be noted that unlike the inline fuel hammer to move the plate in the required direction injection pump which has a static commencement The adjusting plate is turned in the same direction of injection point the point at which commence as the normal direction of the pump rotation to ment of injection occurs in the increase the maximum output Movement of the fuel injection pump varies according to the fuel adjusting plate in the opposite direction will requirements of the engine The timing of the decrease the maximum output This operation pump is carried out with the must be carried out very carefully as the amount pumping plungers set to delivery maximum fuel on of movement required will be very small Tighten No 1 injection line and with the plunger rollers the drive plate securing screws to the torque figure in contact with the cam lobes therefore after all given in GENERALDATA using tools 18G 537 occasions of pump overhaul or adjustment to the and 18G 655A While tightening the screws the pump output it is imperative that the pump timing torque wrench must be in line with the spanner is checked and the timing mark on the pump Fig Ca21 After making this adjustment replace flange remarked if necessary the coverplate and carry out the complete filling Remove the coverplate from the side of the and priming operation Recheck the fuel delivery pump housing and the four redial connections and if necessary readjust the pump output from the hydraulic head Connect injector nozzle testing machine 18G 109 A to outlet V on the10 Fuel delivery hydraulic head to means of relief valve timing Decrease the pump speed to 100 rpm and check adaptor 18G 653 A The relief valve must be set to the output The average delivery for 200 shots operate at 30 atmospheres under these conditions should not be less than Turn the pump drive hub in the normal direction that obtained when setting the pump maximum of rotation until the timing mark E on the drive fuel output minus 15 CC When carrying out this plate becomes visible through the aperture in the test use 30 seconds measuringglass draining time side of the pump housing Operate the handle of and allow the test oil to settle for 15 seconds the test machine to apply a pressure of 30 atmo before taking a reading spheres to the pump This will force the pumpingTaxi Issue 7 83137 Ca17Ca THE FUEL SYSTEM Injection Pump plungers outwards to the limit of their travel as the drive hub is turned Continue turning the drive hub in the normal direction of rotation until resistance is encountered With the pump held in this position mount flangemarking gauge 18G 648A preset to 86 on the pump quill shaft Check that the timing mark on the pump flange lies along the scribing guide on the flange marking gauge If necessary delete the old timing mark and scribe a new mark by drawing a scribing tool along the guide on the flange marking gauge Disconnect the pump from the test machine and fit the banjo pipes to the hydraulic head Refit the coverplate to the side of the fuel pump A57660 housing and seal the securing screws with wire and Fig Ca22 a lead seal using sealing pliers 18G 541 Scribing the timing mark on the fuel injection pump mounting flange using Service tool 18G 648 AMaximum and idling speed adjustments These adjustments are carried out after the pump hasbeen installed on the engine and are detailed in Section When testing the injectors for spray and adjustingCa7 the injectors for service the nozzle opening pres sure should be set to 130 atmospheres for 22litre engines and 135 atmospheres for 252litre enginesSection Ca10 The needle lift should be 029 to 035 in 75 to 90 mm for 22litre engines and 4 to 75 mm for ALTITUDE SETTINGS 252litre engines Each vehicle leaves the Factory with its maximum fuelsetting adjusted for sealevel conditions If the vehicle isto be operated continuously above sealevel adjustmentof the injection pump is necessary to set the maximum Section Ca12fuel delivery to conform with the figures given in thefollowing table LIFT PUMP Follow the instructions given in Section Cl but after replacing the lift pump bleed the fuel system as described Moximum fuel output for 200 in Section Ca5 Altitude 0 to 2000 ft 68 to 70 CC 0 to 600 m Section Ca131 2000 t o 4000 ft 600 t o 1200 m 64 to 66 CC 83 to 85 cc MODIFIED INJECTION PUMP 4000 to 6000 ft 60 t o 62 CC 77 t o 79 CC Type DPA3248050A 1200 to 1800 m This pump is as described in Section Ca6 but with 6000 t o 8000 ft 56 to 58 CC 72 to 74 cc various detail modifications to improve engine governing 1800 to 2400 m and the addition of an antistall device The modifications 8000 to 10000 ft 51 to 53 CC 66 to 68 cc 2400 to 3000 m include a governor spring idling spring and maximum advance stop spring of new load rates Other modifica 10000 to 12000 ft 47 to 49 cc 61 to 63 CC tions incorporated in this pump are to the metering valve 3000 to 3600 m quill shaft and banjo pipes The antistall device consists of an adjusting screw which protrudes from the drive end of the control cover and a locknut In operation the inner end of the adjusting screw contacts the governor arm to act as a stop TheSection Ca11 effect of this is to prevent the governor from reducing the metering area below the position permitted by the FUEL INJECTORS antistall screw Therefore adjustment of the antistall Follow the instructions given in Section C6 noting screw should only be carried out as described in Sectionthe following points Ca13 under Maximum and idling speed Taxi Issue 7 83137 THE FUEL SYSTEM Injection PumpRemoving and replacing of air bubbles in the pipe line If necessary tighten Follow the instructions in Section Ca7 noting that the the feed pipe unions and carry out a further testcorrect injection timing for this pump is 26 BTDC NOTE Do not run the pump for periods ex ceeding 60 seconds with the test oil supply turned offMaximum and idling speed adjustments After the vacuum test is completed turn on the After fitting either a new or overhauled injection pump test oil supply and with the pump running atadjust the engine maximum light running speed as 100 rpm air vent the pump by means of the ventdescribed in Section Ca7 Then proceed as follows to valve on the hydraulic head locking screwadjust the idling speed and antistall device 1 With the engine stopped unscrew the antistall 2 Transfer pump pressure screw until it is out of contact with the governor With the pump running at 100 rpm note the arm pressure registered on the pressure gauge which should read 11 lbsq in 8 kgcm2 2 Start the engine ensure that it is at its normal running temperature and adjust the idling stop 3 Transferpump pressure screw to set the engine speed at between 450 and Increase the pump speed to 1300 rpm when a 500 rpm pressure of 43 to 54 lbsq in 29 to 38 kgcm2 3 Screw in the antistall screw carefully until a slight should be registered on the pressure gauge speed increase is noticed then unscrew one third of a turn and lock in position with the locknut 4 Fuel delivery setting 4 Readjust the idling stop screw to set the idling Run the pump at 1300rpm and after slackening speed at 500 rpm and tighten the idling stop screw the locknut alter the metering valve adjustment locknut screw till a zero reading is obtained on the auto 5 Test the antistall screw setting by running the matic advance gauge Tighten the locknut and engine at about 3000 rpm and then releasing recheck the advance reading Fit shutoff lever the throttle adjustment tool 18G 697 to the fuel pump and a If the engine stalls the pump is underdamped adjust the shutoff lever to obtain an average fuel and the antistall screw should be screwed in delivery of 62 to 70 CC per 200 shots slightly relocked and the setting retested Ensure that the advance gauge still shows a zero b If the engine deceleration is slow or sluggish reading the pump is overdamped and the antistall screw should be screwed out slightly relocked 5 Advance setting and the setting retested Run the pump at 1300rpm Slacken the meter 6 Check that the engine stops when the shutoff lever ing valve adjustment screw locknut and alter the is operated adjustment screw to obtain an advance reading of 134 to 214 Tighten the locknut and recheck the NOTEAfter every adjustment of the antistall screw advance readingensure that the engine idling speed is controlled by theidling stop screw and not by the antistall screw 6 Fuel delivery check Without altering any of the adjustments and reassembling that the fuel delivery at 1300 rpm is 62 to 70 Follow the instructions in Section Ca8 noting that this CC per 200 shots Remove the shutoff leverpump is fitted with four governor weights adjustment toolTesting and adjusting 7 Advance check Mount the pump on a test bench and fill and prime Run the fuel pump at 1300 rpm Move thethe pump as described in Section Ca9 Check the oil shutoff lever to the fully closed position and checktightness of all joint washers oil seals and pipe connec that the advance reading is 33 to 43 Fit and sealtions with the pump running and when stationary Then the metering valve adjustment screw sealing capproceed with the following tests noting that the pump with wire and a lead seal using sealing pliersthrottle arm and shutoff lever must be in the fully open 18G 541position except where stated otherwise NOTEIf for any reason it is found necessary 1 Transfer pump vacuum test to tighten or slacken the governor control cover cap Start the test machine and run the pump at 100 nut the settings made at 4 and 5 will be dis rpm turbed and operations4 5 6 and 7 should Turn the test oil feed cock to the off position be repeated and note the depression registered on the vacuum gauge This should build up to 16in 406 mm Hg 8 Backleakage within 60 seconds maximum Check the fuel feed Set the shutoff lever fully open and the throttle pipe unions for air leaks indicated by the presence arm fully closed Run the pump at 1000 rpmTaxi Issue 5 6394 Ca19 THE FUEL SYSTEM Injection Pump and measure the backleakage through the gradu 11 Cutoff test ated measuringglass The backleakage should be With the shutoff lever held in the fully closed 5 to 50 CC per 100 shot time cycle position run the pump at 200 rpm The average delivery for 200 shots with the throttle arm in the fully open position should not exceed 8 CC Maximum fuel setting 12 Throttle operation With the throttle arm in the fully closed position NOTEThroughout this test the advance gauge must show a zero reading unscrew the antistall screw until it is out of contact with the governor arm and tighten the locknut Run the pump at 1000 rpm with both controls Run the pump at 200 rpm with the throttle arm in their fully open position when the average still fully closed The average delivery with the delivery for 200 shots from all four test injectors shutoff lever fully open should not exceed 10 CC should be 691 CC In arriving at this figure per 200 shots compare the delivery from all injectors to ensure that the difference in output from any two does 13 Fuel delivery check not exceed 6 CC Before taking a reading the test With both controls fully open run the fuel pump oil in the should be allowed to at 1630 rpm and record the average delivery per settle for 15 seconds and the 200 shots should be allowed to drain for 30 seconds before a 14 Governor setting fresh test is made Increase the pump speed to 1850 rpm and set To adjust the pump output stop the test bench the throttle arm by means of the maximum speed and turn the test oil feed cock to the off position adjustment screw to give a maximum average Remove the coverplate from the side of the pump delivery of 10 CC per 200 shots No line should housingto provide accessto the interior of the pump exceed 18 CC Tighten the adjustment screw Slacken the two drive plate securing screws suffi locknut ciently to permit movement of the adjusting plates Turn the pump drive until the slots in the peri 15 Fuel delivery check pheries of the drive plate and the top adjusting Reduce the pump speed to 1630 rpm and re plate are visible through the aperture in the pump check the fuel delivery The average delivery now housing Engage the end of the maximum fuel should not be less than that recorded in operation adjusting probe 18G656 in the slot in the top 13 minus 4 CC per 200 shots adjusting plate and tap the tool with a light hammer to move the plate in the required direction 16 Timing setting The adjusting plate is turned in the same direction This setting is made after all the foregoing tests as normal pump rotation to increase the maximum have been completed with the pump removed from output Movement of the adjusting plate in the the powerdriven test bench opposite direction will decrease the maximum It should be noted that unlike the inline fuel output This operation must be carried out very injection pump which has a static commencement carefully as the amount of movement required will of injection point the point at which commence be very small Tighten the drive plate securing ment of injection occurs in the screws to the torque figure given in GENERAL fuel injection pump varies according to the fuel DATA using tools 18G 537 and 18G 655A requirements of the engine The timing of the dis While tightening the screws the torque wrench tributor type pump is carried out with the pumping must be in line with the spanner Fig Ca21 plungers set to deliver maximum fuel on No 1 After making this adjustment replace the cover injection line and with the plunger rollers in plate and carry out the complete filling and priming contact with the cam lobes therefore after all operation Recheck the fuel delivery and if neces occasions of pump overhaul or adjustment to the sary readjust the pump output pump output it is imperative that the pump timing is checked and the timing mark on the pump flange remarked if necessary Remove the cover plate from the side of the Fuel delivery pump housing and the four radial connections Decrease the pump speed to 100 rpm and check from the hydraulic head Connect injector nozzle the output The average delivery for 200 shots testing machine 18G 109 A to outlet Von the should now be not less than that obtained when hydraulic head by means of relief valve timing setting the pump maximum fuel output minus 15 adaptor 18G 653 A The relief valve should be set CC When carrying out this test use 30 seconds to operate at 30 atmospheres measuringglass draining time and allow the test Turn the pump drive hub in the normal direction oil to settle for 15seconds before taking a reading of rotation until the timing mark E on the driveCa20 T axi Issue 5 6394 THE FUEL SYSTEM Injection Pump Ca plate becomes visible through the aperture in the 5 Lift off the air cleaner body and intake hose as an side of the pump housing Operate the handle of assembly Note the rubber air seal between the the test machine to apply a pressure of 30 atmo cleaner body and the intake manifold on the spheres to the pump This will force the pumping engine plungers outwards to the limit of their travel as the drive hub is turned Continue turning the drive Refitting hub in the normal direction of rotation until 6 Reverse the procedure in 1 to 5 resistance is encountered With the pump held in this position mount flangemarking gauge 18G648A preset to 86 on the pump quill shaft Check that the timing mark on the pump flange lies along the Section Ca16 scribing guide on the flange marking gauge If necessary delete the old timing mark and scribe a INJECTION PUMP 252litre diesel engine new mark by drawing a scribing tool along the The pump is as described in Sections Ca6 and Ca13 guide on the flange marking gauge but with a type number DPA 3249F520 and the setting Disconnect the pump from the test machine and code stamped on the pump nameplate fit the banjo pipes to the hydraulic head Refit the Later engines are fitted with a modified pump This coverplate to the side of the fuel pump housing pump is as described above but with a type number and seal the securing screws with wire and lead DPA 3342F110 and having two springs fitted to the seal using sealing pliers 18G 541 linkage hook instead of a single spring Removing and settings Follow the instructions in Section Ca7 noting that the Follow the instructions in Section Ca10 correct injection timing for this pump is 23 BTDC Maximum and idling speed adjustments Follow the instructions given in Section Ca13 Dismantling and Ca14 Refer to the instructions given in Section Ca13 and Section Ca8 AIR CLEANER Oil Bath Type Testing and Conditionsfor test 1 Release the clips and detach the air inlet tube and 1 The test equipment must be set to drive the pump the breather hose from the air cleaner body 2 Remove the screws retaining the air cleaner in the direction of rotation indicated on the pump assembly to the lefthand valance nameplate 3 Lift out the air cleaner assembly 2 Fuel available at the injection pump inlet must be 1000 ccmin flow minimum or 2 lbsq inRefitting 15 kgcm2pressure maximum 4 Reverse the procedure in I to 3 3 Test injectors must be a matched set with type BDN12SD12 nozzles operating at 175 atmo spheres 4 Injector pipes should be 6 mm x 2 mm x 34 inSection Ca15 865 mm long 5 The injection pump throttle and shutoff levers AIR CLEANER Dry Type must be in the fully open position except whereRemoving otherwise stated 1 Remove the drive screw retaining the air intake 6 All fuel delivery figures are for 200 shots hose clip to the radiator frame 7 Allow 30 seconds glass draining time and 15 2 Release the clip and detach the breather hose from seconds settling time when taking fuel delivery the air cleaner intake readings 3 Remove the central wing nut detach the air cleaner 8 The maximum fuel delivery given in the test plan is top cover and remove the element for sealevel conditions For continuous use above 4 Release the air cleaner body from its support sealevel see Section Ca10 for maximum fuel bracket settingsTaxi Issue 7 94241 Ca21Ca THE FUEL SYSTEM Injection PumpTest plan for pumps DPA 3249F520 and DPA 3342F110 Setting code A45120043700 Test No 1 Description RPM Requirements Remarks Transfer pump vacuum 100 16 in 406 mm Hg Fuel supply turned off After test within 60 seconds airvent from hydraulic vent screw at 100 rpm 1 l 2 Transfer pressure 100 1 1 lbsq in8 kgcm2 minimum Transfer pressure 1200 58 to 78 lbsq in 41to 55 kgcm2 4 5 I Advance position Advance position 1200 1800 to 2 to Use metering valve adjustment screw to obtain this reading Metering valve adjustment as in test 4 Shutoff lever fully closed Lock valve adjustment screw and seal it using tool 18G 541 6 I Backleakage 1200 3 to 50 CC for 1 time cycle 00 stroke Throttle lever fully closed 7 Maximum fuel delivery 1200 90 CC average Adjust output by moving adjusting Spread between lines not plate relative to drive plate with to exceed 10 CC tool 18 G 656 Tighten drive plate screws to correct torque with tool 18 G 655 A I 8 Fuel delivery check Average as test 7 minus This is a minimum delivery figure 32 CC 9 1 Cutoff operation I Average delivery 08 maximum CC Shutoff lever fully closed 11 I1 Throttle operation Fuel delivery check 1650 I1 Average delivery 10 CC maximum Record delivery Throttle lever fully closed and anti stall screw unscrewed and locked 12 Governor setting 1850 Average delivery 18 CC Set throttle lever with maximum maximum No line to speed adjustment screw exceed 25 CC Lock stop screw 13 Fuel delivery check 1650 Average delivery as in This is a minimum figure Throttle test 1 1 minus 04 CC set as in test 12 14 Governor setting 1850 Average delivery of 18 CC Set throttle with maximum speed adjustment screw Lock stop screw Adaptor 18G653 A set at 30 atmospheres connecting 1 8G 109A to outlet V Apply fuel pressure 18G648A set at 86 and mark pump flange with scriberCa22 Taxi Issue 7 94241 KEY TO THE FUEL INJECTION PUMP COMPONENTSNo Description No Description No Description 1 End plate 44 Thrust sleeve 86 Throttle shaft 2 Locating pin 45 Thrust washer 87 Seal for throttle shaft 3 Screw for end plate 46 Drive shaft 88 Dust cap for shaft 4 Stud for end plate 47 Drive shaft seal 89 Nut for shaft 5 Nut for stud 48 Drive shaft screw 90 Throttle arm 6 Piston retaining spring 49 Spring washer for screw 91 Governor spring 7 Regulating piston 50 Support washer 92 Guide for idling spring 8 Regulating sleeve 51 Drive hub 93 Control cover 9 Washer for sleeve 52 Drive hub seal 94 Adjusting screw10 Filter 53 Quill shaft 95 Washer for adjusting screw11 Regulating plug 54 Pump housing 96 Locknut for screw12 Regulating spring 55 Gasket for control cover 97 Locking sleeve13 Sleeve retaining spring 56 Coverplate 98 Adaptor for sleeve14 Inlet connection 57 Gasket for coverplate 99 Vent screw15 Washer for inlet connection 58 Screw for coverplate 100 Vent screw body16 Transfer pump rotor 59 Washer for screw shakeproof 101 Washer for vent screw body17 Transfer pump blade 60 Drain connection 102 Adjustment screw for metering valve18 Transfer pump liner 61 Washer for connection 103 Washer for nut19 Transfer pump seal 62 Governor arm 104 Locknut20 Hydraulic head and rotor assembly 63 Spring for governor arm 105 Sealing cap21 Rotor plug 64 Keep plate 106 Automatic advance device housing and piston22 Washer for plug 65 Tab washer 107 Gasket for housing23 Hydraulic head seal 66 Control bracket 108 Stud for housing24 Banjo pipe 67 Screw for bracket 109 Cap nut for stud25 Bolt for banjo pipe 68 Tab washer for screw 110 Washer for cap nut26 Washer for bolt 69 Stud for control cover 111 Cam advance screw27 Fuel feed pipe connection 70 Nut for stud 112 Piston plug28 Olive for fuel feed pipe 71 Washer for stud 113 Seal for plug29 Hydraulic head locking screw 72 Linkage nut 114 Piston spring cap30 Washer for screw 73 Pivot ball washer 115 Seal for cap31 Hydraulic head vent screw assembly 74 Linkage washer 116 Screw for cap32 Vented locking screw for hydraulic head 75 Linkage hook 117 Washer for screw33 Vent screw 76 Linkage spring 118 Head locating bolt34 Adjusting plate bottom 77 Spring retainer 119 Slide washer35 Roller shoe 78 Metering valve 120 Maximum advance stop36 Roller 79 Shutoff bar 121 Spring for stop37 Adjusting plate top 80 Shutoff Shaft 122 Shim washer for spring38 Drive plate 81 Seal for shutoff shaft 123 Washer for head locating bolt39 Drive plate screw 82 Shutoff lever 124 Joint washer for pump mounting flange40 Cam ring 83 Dust cap for shaft 125 Washer for nut41 Locating circlip for cam ring 84 Washer for shaft 126 Nut for injection pump mounting bolt42 Governor weight 85 Nut for shaft 127 Idling spring43 Retainer for governor weights

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